Title: Optimised methodology for aircraft engine IBRs five-axis machining process

Authors: Egoitz Artetxe; Haizea González; Amaia Calleja; Asier Fernández Valdivielso; Roberto Polvorosa; Aitzol Lamikiz; L. Norberto López De Lacalle

Addresses: Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain ' Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain ' Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain ' Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain ' Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain ' Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain ' Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain

Abstract: Integral bladed rotors (IBRs), such as impeller and blisk, have become five-axis machining reference components. Due to its functional and technical requirements, these parts consist of complex geometry and are manufactured in difficult to cut materials. Despite the recent advances in five-axis machining, these components manufacturing is still a challenge. In the present work a methodology for a reliable machining process of IBRs is proposed. Geometric and process simulations were added to the initial toolpath design process in order to improve obtained part quality. A machine kinematics simulation allowed optimising machining set up. In addition, a mechanical analysis was developed to simulate the cutting forces. Several impeller and blisk geometries were milled to validate and optimise the process.

Keywords: IBR; integral bladed rotors; impellers; blisks; five-axis machining; toolpath design; axial compressors; centrifugal compressors; cutting force; flank milling; point milling; optimisation; aircraft engines; aero engines; component manufacturing; simulation; machine kinematics.

DOI: 10.1504/IJMMS.2016.082873

International Journal of Mechatronics and Manufacturing Systems, 2016 Vol.9 No.4, pp.385 - 401

Received: 20 Nov 2015
Accepted: 29 Jul 2016
Published online: 14 Mar 2017 *

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